Apparatus for applying multicolor surface decoration

ABSTRACT

An apparatus for applying a multicolor image together with a metallized bright foil to a web of mylar cellophane or paper. The surface of an article can then be decorated with the image and foil by transferring, under heat and pressure, the multicolor image and metallized foil from the web in a single operation.

United States Patent 1151 3,648,604 Warsager Mar, 14, 1972 [54] APPARATUS FOR APPLYING 2,497,909 2/1950 Poole ..l0l/l8l MULTICOLOR SURFACE 2,723,682 12/1956 Fulk....M. 2,9 ,73 11961 Borchadsen DECORATION 3,217,637 11/1965 Worth [72] Inventor: Rubin Warsager, 72 Luddington Road, 3,416,444 12/1968 Cahn ..l0l/181 west Orange 07092 FORElGN PATENTS OR APPLICATIONS [22] 1969 1,126,515 9/1968 GreatBritain ..101/228 211 Appl. No.: 792,422

Primary Examiner-J. Reed Fisher AttorneyAlbert C. Johnston, Robert E. lsner, Lewis H.

[52] US. Cl. ....101/l8l,10l/D1G.4,101/244 E A d b d 51 110.01. .341: 5/06, B41f 5/16 S and [58] Field ofSearch., ..101/18l, 180, 202,243, 244, [57] ABSTRACT 101/336,l83, 184

An apparatus for applying a multicolor image together with a [56] References Cited metallized bright foil to a web of rnylar cellophane or paper. The surface of an article can then be decorated with the image UNITED STATES PATENTS and foil by transferring, under heat and pressure, the mult'l d talldf'llf th b' '1 771,900 10/1904 Finch 101 /228 533,331? me mm c we m 3 5mg 8 1,949,362 2/1934 Wickwire, Jr. ..l0l/25 2,151,028 3/1939 Hayward 101/226 3 Claims, 2 Drawing Figures we 3 1' 75 /5 FPS/{LL02 TAKE 4/7 2 ga Ffl/L 3 F0/L 742 52:

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ATTOZ/Vfl N NE UQQRNWQ QQK W QQ U QVF ME mm\ APPARATUS FOR APPLYING MULTICOLOR SURFACE DECORATION BACKGROUND OF THE INVENTION In the prior art when it was desired to apply a plurality of colors or a decoration consisting of a plurality of colors to an object such, for example, as the surface of a plastic bottle, it was necessary to apply each color separately. For example, if it was desired to apply a decoration to the surface of a bottle and the decoration contained the colors blue, green and gold, it was necessary to apply the blue in one pass, the gold on the second pass and finally the green on the third pass, all in separate operations. This was accomplished by applying a hot stamping leaf of the desired color to the surface of the article to be decorated. In applying a decoration by means of a hot stamping leaf, pressure and heat are applied to the leaf and because of this heat and pressure the material on the leaf adheres to the surface to be decorated. It should be noted that the leaf is generally a foil and contains a solid color, and the design transferred depends on the configuration of a die which applies the pressure. Therefore, if two or more colors in registration are to be applied by such roll leaf process, the part to be decorated must be inserted in the hot stamping press for each different color, the roll leaf replaced by the next color, the die replaced and another hit made. While this process can be economical in one color decorations, machine and labor time become high with multicolor work and great care must be taken that the various colors register properly on the article to be decorated.

It is essential that the mechanism for producing a web having a multicolor image together with a metallized foil must be able to register the design and colors perfectly to produce a good transfer from the web to the article to be decorated.

In an attempt to simplify the multicolor decoration of the surface of an article, the use of decals or heat transfers was evolved. A multicolor heat transfer consists of designs, letters, trademarks, etc., preprinted in reverse on a carrier paper or web which is coated with a release material. The ink image, whatever the number of colors, is transferred in one operation under heat and pressure from a transfer platen to a product, after which the carrier paper is discarded. The multicolor transfers can all be applied in hot stamping machines of either press or roll type. A multicolor transfer, therefore, applies all colors in the decoration in one hit. Therefore, machine and labor time are not proportional to the number of colors and separate dies and pigment rolls for each color are not necessary.

Applying roll leaf decoration in hot stamping presses has the advantage that once the decorated part is properly placed in a located fixture the image transferred by the die will automatically be properly registered on the surface to be decorated. Multicolor transfers can, therefore, be applied on existing hot stamping machines which are equipped with the necessary locating devices. These decals, it is to be noted, are prepared of a base or web and the multicolor image is printed on the paper base usually by means ofa rotogravure press. In the case of a multicolor image a rotogravure plate has to be prepared for each image. This has the inherent difficulty that each color must be registered with the other.

In the prior art when it was desired to obtain a roll leaf metallic impression as part of the surface decoration, this was applied over or under the other transfer as another operation, The reason for this is that it is considered impossible to vacuum plate a metallic material on a paper surface. The hot stamping leaf for this purpose is generally composed of a plastic base material or web such as mylar or cellophane. One surface of this web is first coated with a heat and pressure sensitive release material so that when heat and pressure are applied to the web whatever has been superimposed on the heat sensitive release will be released and will adhere to the surface to be decorated. The metallized finish such as silver or gold is applied to the web by means of vacuum deposition. The prior art, however, has never used a registered multicolor design in conjunction with a plastic base material which also has applied thereto a metallic surface.

In summary, therefore, when the carrier web consists of paper it can have applied thereto a multicolor design by means of any well known printing process. If in addition, it is desired to have a metallic impression this must be done over or under the transfer before or after it has been completed as a secondary operation. This secondary operation is accomplished by means of another web which is made from a plastic material such as mylar or cellophane and which has applied thereto a metallized bright foil such as gold or silver by means of vacuum metallizing.

SUMMARY OF THE INVENTION A mylar cellophane or paper web of material is first coated with a known release material and placed on a spool. The web is fed continuously through a die or over a sprocket which uniformly perforates the web. The web is picked up by a sprocket at each of a plurality of stations. The space between the fingers on the sprocket is uniform at each station. Since the spacing of the perforations is uniform, the proper registration of the image and the foil on the web is insured. The maintenance of perfect registration can be accomplished using any mechanical or electronic means.

From the perforating die, the web is then fed into a first stage where a rotary stamping die places a first color foil on the web in proper registration with an image previously placed on the web. The web is then fed into succeeding stages where additional colored foils can be applied to the web. At each stage, there is provided an adjustment mechanism to enable the operator to control the placement of the colors on the web.

After the web has passed through the final stage thereby receiving the last color to be applied thereto, the web is fed into a vacuum metallizing chamber. The surface of the web is colored by a metallized bright foil such as gold, silver aluminum or other metal. This is accomplished by passing the web through a vacuum chamber such that the thin metal surface is applied on the entire surface of the web over the heat release material and the multicolor image printed thereon. It is to be understood that the metallic colors can also be applied by hot stamping in specific areas at one or more of the stations.

The last operation in making the multicolor foil is the application of an adhesive or sizing which insures adhesion of the foil to the article to be decorated. The adhesive can be applied by hot-stamping it onto specific areas or by utilizing an overall roller coating.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic flow diagram showing a web fed through a number of stations;

FIG. 2 is a cross-sectional view showing the details of a station.

Referring to FIG. 1, there is shown a flow chart indicating the path of travel of a web 12 through a plurality of stations 150, b and c. The web, which can be a plastic such as mylar or cellophane, is placed on a drum 10 which is freely rotatable about a shaft 11. The web 12 is treated with a known release material such that when heat is applied. to the release material any matter printed on the material will no longer adhere to the web.

Perforations are placed on either one or both sides of the web by a pair of drums 13 in which one drum has a plurality of spaced sprockets 14 thereon which pierce the web 12. The sprockets are spaced apart the distance which one desires to make the perforations on the web. Alternatively the first station I5 can have sprockets on a rotating member such as the mandrel 18 to perforate the web 12 thereby eliminating the rollers 13. Prior to reaching the first station 15, free wheeling shafts 16 having sprockets thereon can be employed to insure that the web does not slip. The sprockets are spaced thereon the same distance as on the drum l3.

Since a plurality of stations can be used, and since each station is identical, only one will be described therein. The station comprises a base 17 as shown in FIG. 2, which can be cast iron, plastic or any other material. Rotatably mounted on a shaft 18a is a mandrel 18. The mandrel preferably has a rubberized or othersurface having a relatively high coefficient of friction to enable it to grip the web 12. Mounted on diametrically opposite ends of the mandrel 18 are shafts 19 upon which are rotatably mounted pressure rollers 20a and b, respectively, which also have a surface having a high coefficient of friction, preferably the same surface as the mandrel.

The mandrel 18 can have sprockets l4 thereon which serve to perforate the web 12 along one or both edges as desired. The mandrel 18 can be driven by an electric motor at a constant speed to pull the web through the station or a motor can drive a takeup spool at the last station, or any other motive means, including manual actuation, can be used.

A rotary die 21 is rotatably mounted on the shaft 22. The die can be absolutely smooth or it can have a raised surface thereon to permit a design to be transferred. The rotary die can be made of metal, rubber, plastic or any other suitable material. The shaft 22 is reciprocably mounted in a yoke 23 so as to be adjustable therein. Thus, when the operator desires to increase the pressure between the mandrel 18 and the die 21, he merely turns the screw 24. The screw has a longitudinal bore therein which receives a coiled spring 25. As the screw 24 is turned into the die 21, the spring 25 is compressed and a force is exerted against the die 21 thereby increasing the pressure between the mandrel 18 and the die 21. A number of bolts 26 hold the cover 27 on the yoke 23. A pair of idler rollers 28a and 28b are rotatably mounted on the base 17 which guide the foil between the mandrel 18 and the die 21. The surface of the idler rollers has a high coefficient offriction.

A supply drum 29 is rotatably mounted in an open journal 30 on a shaft. The journal is integral with the arm 31 on the base 17. The supply spool 29 has a colored foil 32 thereon and each of the subsequent stations have a different colored foil on their respective supply drums. The foil 32 fits around the idler roller 28a and then passes between the mandrel 18 and the die 21 to the idler 28b. The foil 32 is then received between the pressure rollers 33 which are rotatably mounted on shafts 34 journaled on the base 17. The pressure rollers 33 preferably have rubber surfaces or other material having a high coefficient of friction to grip the foil 32. The takeup drum 35 isjournaled on the base 17 in the same manner as the supply drum 29. Since the foil 32 is on a tape, the remaining portion of the foil which was not transferred to the web 12 is fed to the takeup drum 35.

The web 12 is fed between the pressure roller 20a and the mandrel 18, thence between the mandrel and the die 21 from which it passes between the opposite pressure roller 20b, and the mandrel 18 on to the next station, where a second colored foil can be applied over the release material onto the web 12.

Also mounted on the base 17 is a takeup adjustment. In the event that it becomes necessary to change the location of the foil at the second or subsequent stations with respect to the web 12, the takeup adjustment will accomplish this. A worm 36 is mounted on a shaft 37 which is driven by a crank 38. Rotation of the crank causes the worm to rotate which drives the worm gear 39 mounted on a shaft 40 which is journaled on the base 17. A narrow arm 41 is fixed to the shaft 40 and rotates therewith. On the end of the arm opposite the shaft 40 there is rotatably mounted an idler roller 42 on a shaft 43. Thus when it is desired to alter the registration of the colored foil 32 on the web 12, the operator turns the crank 38 which rotates the worm 36, turning the worm gear 39. The arm 41 will then be raised or lowered depending upon the direction of rotation. Since the idler roller 42 is fixed to the arm, it will be raised or lowered therewith. The web 12 lies in the path of travel of the idler roller and is thereby raised or lowered by the idler depending on its position. When it is raised, this will, of course, lengthen the web thereby affecting the registration of the sprockets with the perforations at the subsequent station.

In actual operation, a supply drum 10 having a mylar or cellophane web which was treated with a release material is threaded either into a perforating die 13 or it goes around a pressure roller 20 and then is perforated by a mandrel 18. A supply drum 29 having a colored foil 32 thereon is threaded around the idler 28 between the die 21 and the mandrel 18 around the idler 28 between pressure rollers 33 and thence to the takeup drum 35. When the mylar web 12 is fed between the die 21 and the mandrel 18 the pressure of the die is adjusted by turning the hex. head screw 24. The foil is then brought into contact with the web 12 and the die passes the design on its face to the web 12 or if the die is flat, the foil is transferred to the web. The web is then passed between the mandrel 18 and the pressure roller 20 to the next station which is identical to the first except that a different colored foil is on the supply drum 29 which is then transferred in it proper position to the web 12.

Because the web is perforated and each station has one or more members having sprockets which engage the perforations, there is assurance that the next color applied to the web 12 will register properly. If, on the other hand, an adjustment must be made then the operator can do so by rotating the crank 38. This actuates a worm which operates to put an idler roller 42 in contact with the web to lift or lower the latter. After the web has passed through all the stations it goes into a known vacuum metallizing chamber 43 where a metallic foil is applied over the other colors. A backing coat, or sizing or adhesive is placed on the thin metal plate which is the last step in the process, and then a completed web is obtained which can be used to decorate an article such as a perfume bottle with one pass. The adhesive can be applied by hot stamping it onto specific areas or by using an overall roller coating. The adhesive, which can be any known material, insures adhesion of the foil to the article to be decorated.

While there has been shown and described a particular embodiment of the present invention, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the invention in its broader aspects, and it is therefore contemplated in the appended claims to cover all such changes and modifications as fall within the true spirit and scope of the invention.

1 claim:

1. In an apparatus for applying a multicolor design in a metallic foil to a web passing through said apparatus and having a release coating on one side thereof for transferring said design to an article, independent means respectively located at a plurality of stations in said apparatus for applying colored foils on the release coating of said web, said means comprising a base, a mandrel mounted on said base, means for receiving said web and for moving it through said base and over said mandrel, with the aide of said web opposed to said release coating engaging said mandrel, said receiving means including a first roller having a surface thereon which grips the web between the roller and the mandrel, and a second roller having a surface thereon which grips the web between the roller and the mandrel with said rollers being located on diametrically opposite sides of said mandrel, supply means on said base for storing and receiving a tape having a releasable color foil on one side thereof and for moving said tape continuously over said mandrel, and means opposite said mandrel engaging said tape on the side thereof opposite said foil for applying pressure to said mandrel and urging said foil into engagement with said web for transferring said foil to said web, said pressure applying means including a rotary die having a shaft mounted on the base, a yoke on the base in which the rotary die is reciprocally mounted and spring means mounted on the yoke for applying pressure to the rotary die and means for compressing the spring.

2. An apparatus for applying a multicolor design as defined in claim 1 in which an adjustment mechanism is located at each station to vary the spacing of the web between each respective station.

3. Apparatus as defined in claim 2 wherein said adjustment mechanism comprises means for raising and lowering the web including a rotatably mounted worm gear, a roller adapted to engage said web and being mechanically linked to said worm gear and means for actuating said worm gear to effect raising 5 and lowering of said lifting member. 

1. In an apparatus for applying a multicolor design in a metallic foil to a web passing through said apparatus and having a release coating on one side thereof for transferring said design to an article, independent means respectively located at a plurality of stations in said apparatus for applying colored foils on the release coating of said web, said means comprising a base, a mandrel mounted on said base, means for receiving said web and for moving it through said base and over said mandrel, with the side of said web opposed to said release coating engaging said mandrel, said receiving means including a first roller having a surface thereon which grips the web between the roller and the mandrel, and a second roller having a surface thereon which grips the web between the roller and the mandrel with said rollers being located on diametrically opposite sides of said mandrel, supply means on said base for storing and receiving a tape having a releasable color foil on one side thereof and for moving said tape continuously over said mandrel, and means opposite said mandrel engaging said tape on the side thereof opposite said foil for applying pressure to said mandrel and urging said foil into engagement with said web for transferring said foil to said web, said pressure applying means including a rotary die having a shaft mounted on the base, a yoke on the base in which the rotary die is reciprocally mounted and spring means mounted on the yoke for applying pressure to the rotary die and means for compressing the spring.
 2. An apparatus for applying a multicolor design as defined in claim 1 in which an adjustment mechanism is located at each station to vary the spacing of the web between each respective station.
 3. Apparatus as defined in claim 2 wherein said adjustment mechanism comprises means for raising and lowering the web including a rotatably mounted worm gear, a roller adapted to engage said web and being mechanically linked to said worm gear and means for actuating said worm gear to effect raising and lowering of said lifting member. 